Vortex flowmeter providing extended flow rate measurement

ABSTRACT

A vortex flowmeter for measuring a flow rate of a fluid. The meter includes a flowtube, a bluff body, and a vortex sensor. The bluff body, which is positioned in the flowtube, sheds vortices in the fluid when the fluid flows through the flowtube and the vortex sensor detects the vortices and generates a vortex signal representing the detected vortices. A pressure sensor arrangement is configured to detect a differential pressure in the fluid between a first location upstream of at least a portion of the bluff body and a second location downstream of at least a portion of the bluff body and generate a differential pressure signal representing the pressure differential between the two locations. The flowmeter determines the fluid flow rate based on the pressure differential.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No. 17,179,580, filed Feb. 19, 2021, which claims priority from U.S.Provisional Patent Application No. 62/988,773, filed Mar. 12, 2020, theentire disclosures of which are incorporated herein by reference.

FIELD

The present disclosure generally relates to a vortex flowmeter formeasuring the flow rate of a fluid, and more particularly, the presentdisclosure pertains to a vortex flowmeter with a sensor configured todetect the differential pressure at locations upstream and downstream ofthe bluff body.

BACKGROUND

Flowmeters may measure the rate of flow of a fluid in a pipe or otherpathway. The fluid may be, for example, a gas or a liquid, and may becompressible or incompressible. One type of flowmeter is a vortexflowmeter, which measures flow rate based on the principle of vortexshedding. Vortex shedding refers to a natural process in which a fluidpassing a bluff body (sometimes referred to as a shedder) causes aboundary layer of slowly moving fluid to be formed along the surface ofthe bluff body. A low pressure area is created behind the bluff body andcauses the boundary layer to roll up, which generates vortices insuccession on opposite sides of the bluff body. Unfortunately, theprinciple of operation of a vortex flowmeter requires a minimum Reynoldsnumber based on the velocity, density, and viscosity of the fluid beingmeasured. This means that for a given fluid, a vortex flowmeter has aminimum velocity limit in order to measure flow rates.

SUMMARY

Aspects of the present disclosure recognize that vortices inducepressure variations that may be sensed by a pressure sensor and, underturbulent flow conditions, the vortex-shedding pressure variations havea frequency that is related to the flow rate. Accordingly, by measuringthe frequency of the pressure variations, the flow rate may bedetermined. A vortex flowmeter embodying aspects of the presentdisclosure measures fluid flow by using the vortex flowmeter's shedderbar as a pressure drop element. A beta ratio (β) calculated for a givenshedder geometry can then be used in conjunction with a differentialpressure measurement to calculate flow rates, even at relatively lowvelocities below the conventional limit of vortex shedding.

In an aspect, a vortex flowmeter for measuring a flow rate of a fluidincludes a flowtube, a bluff body, and a vortex sensor. The bluff body,which is positioned in the flowtube, sheds vortices in the fluid whenthe fluid flows through the flowtube and the vortex sensor detects thevortices and generates a vortex signal representing the detectedvortices. A pressure sensor arrangement is configured to detect adifferential pressure in the fluid between a first location upstream ofat least a portion of the bluff body and a second location downstream ofat least a portion of the bluff body and generate a differentialpressure signal representing the differential pressure.

In another aspect, a vortex flowmeter for measuring a flow rate of afluid comprises a flowtube and a bluff body positioned in the flowtube.The flowmeter also includes one or more sensors configured to generatesignals representing characteristics of the fluid as it flows throughthe flowtube past the bluff body. A measurement processor generates aflow rate output representing the flow rate of the fluid based on thesignals from the one or more sensors when the fluid has a Reynoldsnumber of less than 2000.

In yet another aspect, a method of determining a total quantity of fluidin a batch process comprises detecting vortices shed by a bluff bodypositioned in a flowtube of a vortex flowmeter as the fluid flows acrossthe bluff body during the batch process and detecting a differentialpressure across the bluff body during the batch process. The methodfurther includes determining a first amount of fluid that flows past thebluff body during an initial portion of the batch process based on thedetected differential pressure, determining a second amount of fluidthat flows past the bluff body during a middle portion of the batchprocess based on the detected vortices, and determining a third amountof fluid that flows past the bluff body during a final portion of thebatch process based on the detected differential pressure.

Other objects and features of the present invention will be in partapparent and in part pointed out herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a vortex flowmeter according to anembodiment;

FIG. 2 is a longitudinal cross section of a subassembly of the vortexflowmeter of including a flowtube and a bluff body and schematicallyillustrating a differential pressure sensor of the vortex flowmeter; and

FIG. 3 is a flowchart illustrating an example process of providing aflow rate output using the vortex flowmeter.

Corresponding reference numbers indicate corresponding parts throughoutthe drawings.

DETAILED DESCRIPTION

Referring now to FIGS. 1 and 2 , one embodiment of a vortex flowmeterfor measuring fluid flow rate is generally designated 101. The vortexflowmeter 101 includes a flowtube 103 through which a fluid can flow.The flowtube 103 is suitably configured for installation in a fluid flowline (not shown). For example, the flowtube 103 includes processconnections 105 on opposite ends for connecting the inlet 107 (FIG. 2 )and outlet 109 of the flowtube to the ends of pipes in a pipeline. Inone or more embodiments, the process connections 105 can be adapted fora wafer connection, a flange connection, threaded connections, NPTconnections, or any other suitable type of connection. As described indetail below, the vortex flowmeter 101 provides vortex frequency datathat can be used in conjunction with flow calibration factors todetermine the velocity and volumetric flow rate of the fluid passingthrough the meter. With inputted fluid density values, the mass flowrate can also be computed. These measurements, and others, can betransmitted to a control room or other receiver over a communicationline, such as, for example, a standard two-wire 4-20 milliamp (“mA”)transmission line.

As shown in FIG. 2 , in the illustrated embodiment the flowtube 103includes a main tube member 103A formed from a single piece of materialand first and second end pieces 103B that are joined (e.g., welded) tothe ends of the main tube member. The flowtube 103 has an axis A, andthe main tube member 103A has a length L that extends along the axis Aof the flowtube. The process connections 105 are integrally formed withthe end pieces 103B in the illustrated embodiment. Although theillustrated flowtube 103 has a three-piece construction, other flowtubescan be constructed from any suitable number or arrangement of pieces.

Referring still to FIG. 2 , a bluff body 121 (sometimes referred to inthe industry as a vortex shedder or shedder bar) is positioned in theflowtube 103. The bluff body 121 is a structure that is positioned inthe fluid flow so it extends into the flowtube 103 for the purpose ofgenerating vortices in the fluid when the fluid flows through theflowtube. Those skilled in the art recognize that the size and shape ofthe bluff body can vary. Broadly speaking, the bluff body can have anyconfiguration as long as it is able to generate vortices in a fluidstream flowing past the bluff body. When the fluid is flowing throughthe flowtube 103 under turbulent flow conditions, the frequency of thevortices is proportional to the velocity of the fluid. Assuming thecross sectional flow area of the flowtube 103 is constant, the frequencyof vortices is also proportional to the volumetric flow rate. Moreover,if the density of the fluid is known or measured, the mass flow rate canbe derived from the volumetric flow rate.

As shown in FIG. 2 , the vortex flowmeter 101 includes a vortex sensor131 positioned to detect vortices generated by the bluff body 121. Asillustrated, the vortex sensor 131 is suitably positioned at the top ofthe bluff body 121. In this embodiment, the vortex sensor 131 is indirect contact with fluid flowing through the flowtube 103. This allowsthe vortex sensor 131 to sense vortices directly. However, it iscontemplated that the vortex sensor can be positioned to sense vorticesindirectly, such as by detecting movement of the bluff body or otherstructure that is designed to flex or otherwise move in response topressure fluctuations associated with the vortices formed in the fluid.In the illustrated embodiment, the vortex sensor 131 is a differentialpressure sensor that uses piezoelectric transducers to sense vortices.Suitably, the sensor 131 is mounted in the bluff body 121 so that thesensor is exposed to fluid on both lateral sides of the bluff body. Assuch, the sensor can detect pressure differences in pressure on oppositelateral sides of the bluff body 121. So as vortices form in alternatingfashion on opposing lateral sides of the bluff body, the sensor 131registers the fluctuation in differential pressure between the lateralsides of the bluff body and generates a generally sinusoidal vortexsignal.

As those skilled in the art will appreciate, when the fluid flowingthrough the flowtube 103 is turbulent (e.g., has a Reynolds numbergreater than or equal to about 2900) or somewhat turbulent (e.g., has aReynolds number greater than or equal to about 2300), the vortices willalternate at a frequency that is proportional to the flow rate. Thus, asshown in FIG. 1 , the illustrated flowmeter 101 comprises a transmitter141 that includes a measurement processor 142 (shown schematically) thatis operatively connected to the vortex sensor 131 to receive the vortexsignal. Generally, the measurement processor 142 is configured todetermine the frequency of the vortex signal and use the determinedfrequency to calculate a flow rate at which the fluid is flowing throughthe flowtube 103 (e.g., a fluid flow velocity output, a volumetric flowrate output, and/or, a mass flow rate output).

In an embodiment, the transmitter 141, which can be analog or digital,is configured to communicate or output the determined flow rate to adistributed control system (not shown) using protocols such as, but notlimited to, 4-20 mA output, HART, Foundation Fieldbus, and Modbus. Themeasurement processor 142 may include a processor-readable mediumstoring code representing instructions to cause the processor to performa process. The processor 142 may be, for example, a commerciallyavailable microprocessor, an application-specific integrated circuit(ASIC) or a combination of ASICs, which are designed to achieve one ormore specific functions (e.g., determine a flow rate based on one ormore sensor signals), or enable one or more specific devices (e.g., thetransmitter 141) or applications. In yet another embodiment, measurementprocessor 142 may be an analog or digital circuit, or a combination ofmultiple circuits. The measurement processor 142 can also include one ormore memory components (not shown) for storing data in a formretrievable by the processor. For example, the memory can storeprocessor-executable software that is executed by the processor 142 toperform a flow rate measurement process.

In one or more embodiments, the measurement processor 142 is configuredto execute a flow rate measurement process that activates a low flowcutoff when the frequency of the vortex signal is less than a thresholdlow flow cutoff frequency. When the fluid flowing through the flowtube103 is non-turbulent, the frequency of the vortex signal will not relateto the flow rate of the fluid in a predictable fashion, so a low flowcutoff frequency is chosen to be the lower bound at which the flowmeter101 will output a flow rate measurement based on the vortex signal. Forexample, in one or more embodiments, the low flow cutoff frequency ischosen to generally correspond to a flow rate of the fluid through theflowtube 103 at which the fluid has a Reynolds number of somewhereroughly between 2000 and 3000. When the frequency of the vortex signalis greater than the low flow cutoff frequency, the measurement processor142 outputs a flow rate signal based on the vortex signal. But when thefrequency of the vortex signal is less than the low flow cutofffrequency, the measurement processor 142 does not output a flow ratesignal based on the vortex signal.

The inventors have recognized that the low flow cutoff of a vortexflowmeter can lead to inaccuracies in flow measurement. At a basiclevel, the flowmeter will fail to register any flow that occurs at asufficiently low rate to trigger the low flow cutoff. The failure toregister low flow rates can be particularly consequential in fluid batchprocesses in which a flowmeter is used to provide an indication of thetotalized flow of fluid in a batch process that begins and ends at zeroflow and must ramp up to and ramp down from a flow rate that exceeds thelow flow cutoff during the limited duration of the batch. In batchprocesses, a vortex flowmeter can completely fail to account for theflow during the ramp-up and ramp-down intervals, which during short,low-flow rate batches, can cause substantial inaccuracies in thetotalized flow rate measurement.

Referring still to FIG. 2 , the illustrated flowmeter 101 furthercomprises a pressure sensor arrangement 201 (shown schematically)configured to detect a differential pressure in the fluid between afirst location L1 upstream of a portion of the bluff body and a secondlocation L2 downstream of at least a portion of the bluff body. Theinventors have recognized that, even when the fluid flowing throughflowtube 103 is entirely laminar (has a flow rate that will trigger thelow flow cutoff), this pressure differential across the bluff body canhave a predictable relationship to flow rate. Thus, in one or moreembodiments, the pressure sensor arrangement 201 is configured togenerate a differential pressure signal representing the pressuredifferential between the upstream and downstream locations L1, L2 andprovide the differential pressure signal to the measurement processor142. As will be explained in further detail below, the measurementprocessor 142 is configured to use the differential pressure signal tooutput a differential pressure signal-based flow rate measurement whenthe frequency of the vortex signal is less than the low flow cutofffrequency and/or to verify that the vortex sensor 131 is providing anaccurate representation of flow rate.

In the illustrated embodiment, the pressure sensor arrangement 201comprises a single differential pressure sensor unit 203 that isconfigured to directly measure the differential pressure between theupstream and downstream locations L1, L2, respectively. The differentialpressure sensor unit 203 includes a sensing diaphragm 205 having a firstside and an opposite second side. First passaging 207 is configured toconvey a pressure from the upstream location L1 to the first side of thesensing diaphragm 205, and second passaging 209 is configured to conveya pressure from the downstream location L2 to the second side of thesensing diaphragm. A differential pressure between the upstream anddownstream locations L1, L2 thus imparts imbalanced forces on theopposite sides of the sensing diaphragm 205. The sensing diaphragm isconfigured to deform in response to the imbalanced forces, and a sensingelement (e.g., a piezoelectric strain gauge; not shown) is configured todetect the deformation of the sensing diaphragm and thereby produce asignal proportional to the differential pressure.

In the illustrated embodiment, the first passaging 207, whichcommunicates pressure from the upstream location L1 to the first side ofthe sensing diaphragm 205, comprises a hole formed in the bluff body 121at the upstream location L1 to form a pressure tap. Additional holes inthe bluff body 121 and the flowtube 103, as well as other tubing,together define an open fluid passage that extends from the pressure tapat the upstream location L1 to an isolation diaphragm 211 on a firstside of the differential pressure sensor unit 203. The first passaging207 further comprises an isolation passage 213 that fluidly connects theisolation diaphragm 211 to the first side of sensing diaphragm 205. Theprocess fluid in the flowtube 103 can flow into the open fluid passagethrough the pressure tap at the upstream location L1, which conveys thepressure at the upstream location L1 to the isolation diaphragm 211. Theisolation diaphragm is configured to deform in response to pressureimparted on it by the process fluid. The isolation passage 213 is filledwith oil or other pressure-conveying fluid that conveys the pressure tothe first side of the sensing diaphragm 205 in response to thedeformation of the isolation diaphragm 211.

The second passaging 209, which communicates pressure from thedownstream location L2 to the second side of the sensing diaphragm 205,comprises a hole formed in flowtube 103 at the downstream location L2 toform a pressure tap. This hole and additional tubing together define anopen fluid passage that extends from the pressure tap at the downstreamlocation L2 to an isolation diaphragm 215 on a second side of thedifferential pressure sensor unit 203. The second passaging 209 furthercomprises an isolation passage 217 that fluidly connects the isolationdiaphragm 215 to the second side of the sensing diaphragm 205. Theprocess fluid in the flowtube 103 can flow into the open fluid passagethrough the pressure tap at the downstream location L2, which conveysthe pressure at the downstream location to the isolation diaphragm 215.The isolation diaphragm is configured to deform in response to pressureimparted on it by the process fluid. The isolation passage 217 is filledwith oil or other pressure-conveying fluid that conveys the pressure tothe second side of the sensing diaphragm 205 in response to thedeformation of the isolation diaphragm 215.

Although the illustrated embodiment uses open fluid passages formedthrough the bluff body 121 and flowtube 103 to provide fluidcommunication between the pressure tap locations L1, L2 and the externalisolation diaphragms 211, 215, it is contemplated that the differentialpressure sensor unit can have other configurations. For example, in oneor more embodiments, the flowmeter includes isolation diaphragmsimmediately adjacent the upstream and downstream pressure tap locationsL1, L2 and the passaging that conveys the pressure from the upstream anddownstream pressure tap locations to the sensing diaphragm isessentially entirely filled with pressure-conveying fluid that isisolated from the process fluid.

It will be understood other pressure sensor arrangements besides asingle differential pressure sensor unit may be used in one or moreembodiments. For example, it is expressly contemplated that the pressuresensor arrangement can comprise a first line pressure sensor that isconfigured to detect a first line pressure at the upstream pressure taplocation, a second line pressure sensor that is configured to detect asecond line pressure at the downstream pressure tap location, and ameasurement circuit that is configured to determine a difference betweenthe first line pressure and the second line pressure.

It can be seen that the pressure sensor arrangement 201 for detecting adifferential pressure across the bluff body 121 has been integrateddirectly into the vortex flowmeter 101 via pressure taps that are formedintegrally with the meter. In one or more embodiments, the pressure tapsare each located at respective locations L1, L2 along the length L ofthe same unitary piece 103A of the flowtube 103. Further, in theillustrated embodiment, the pressure sensor arrangement 201 ispermanently mounted on the flowtube 103 in an integrated housing 221.The pressure sensor arrangement 201 cannot be removed from theillustrated flowmeter 101 without exposing the integrated pressure tapsto direct fluid communication with the external environment, whicheffectively renders the flowmeter 101 inoperable.

Moreover, the illustrated flowmeter 101, including both the vortexsensor 131 and the pressure sensor arrangement 201, forms an integratedflow rate measurement instrument that may be installed in a pipe andconnected to a distributed control system in unitary fashion. Forexample, only the two process connections 105 at the ends of theflowtube 103 must be secured to the pipe to simultaneously operativelyconnect both the vortex sensor 131 and the pressure sensor arrangement201 to the pipe. Likewise, in one or more embodiments, only one set ofhardwire contacts of the transmitter 141 is connected to the distributedcontrol network (or a single-point wireless connection is made betweenthe transmitter 141 and the distributed control network) to enableoutputs based on both the vortex sensor 131 and the pressure sensorarrangement 201.

In the illustrated embodiment, the upstream pressure tap location L1 islocated on an upstream end face 121A of the bluff body 121 and thedownstream pressure tap location L2 is spaced apart from the upstreamend face of the bluff body along the longitudinal axis A of the flowtube103 in a downstream direction by a distance DD. It is also to beunderstood that, instead of the upstream pressure tap location L1 on theend face 121A of the bluff body 121, an upstream pressure tap locationL1′ may be used that is spaced apart from the upstream end face of thebluff body by a distance UD. Pressure taps formed in the flowtube wall(e.g., at locations L1′, L2) may be located at circumferential regionsof the flowtube wall that are in line with the bluff body or that arecircumferentially offset from the regions of contact between the bluffbody and the flowtube wall. As demonstrated in the examples below, ithas been found that a flow-induced differential pressure is detected ateither circumferential location.

In general, the differential pressure induced by the process fluidflowing across the bluff body 121 at low flow rates is relatively small.Thus, it may be desirable to locate the upstream and downstream pressuretaps at locations where the differential pressure is most pronounced sothat changes in differential pressure attributable to changes in flowrate can be more easily and reliably detected using a less sensitive,and thus less expensive, pressure sensing arrangement 201. It isbelieved that the differential pressure is greatest between an upstreamlocation L1 on the upstream end face 121A of the bluff body 121 and adownstream location L2 that is spaced apart from upstream end face ofthe bluff body by a particular distance that will vary by application,depending on factors such as the pipe line size, the inner diameter IDof the flowtube 103, the type of process fluid, and the size and shapeof the bluff body. In one or more exemplary embodiments, however, thedistance DD between the upstream end face 121A of the bluff body 121 andthe downstream pressure tap location D2 is in an inclusive range of fromabout 0.333-times the inner diameter ID of the flowtube to about5.0-times the inner diameter (e.g., for a flowtube having a diameterfrom about 0.75 inches to about 5.0 inches).

Although forming the upstream pressure tap at the location L1 on theupstream end face 121A of the bluff body 121 is believed to enabledetection of the greatest differential pressures, in some cases it maystill be desirable to use the alternative upstream pressure tap locationL1′. For example, when the process fluid contains paraffin or lipids,such materials may clog the upstream pressure tap when it is located atthe location L1 on the upstream end face 121A. In one or moreembodiments, therefore, an upstream pressure tap location L1′ isselected that is spaced apart from the upstream end face 121A by thedistance UD. In one or more embodiments, the distance UD is in aninclusive range of from about 0.0-times the inner diameter ID of theflowtube to about 4.75-times the inner diameter (e.g., for a flowtubehaving a diameter from about 0.75 inches to about 5.0 inches).

Referring now to FIG. 3 , exemplary control logic that may be executedby the measurement processor 142 to provide a flow rate output based onthe vortex signal from the vortex sensor 131 and the differentialpressure signal from the differential pressure sensing arrangement 201is illustrated schematically at 301. As explained above, during use, themeasurement processor 142 is operatively connected to the vortex sensor131 to receive the vortex signal and the differential pressure sensingarrangement 201 to receive the differential pressure signal. At aninitial step 303, the measurement process 142 determines the frequencyof the vortex signal for purposes of comparing the determined frequencyto the threshold low flow cutoff frequency at 305. If the vortex signalfrequency is determined to be less than the low flow cutoff frequency,at step 307, the measurement processor 142 determines the flow ratebased on the differential pressure signal from the differential pressuresensor 203. Those skilled in the art understand how to empiricallyderive mathematical equations for calculating a flow rate based on adifferential pressure in a fluid flowing across a flow obstruction. Themeasurement processor 142 can use any suitable mathematical equationthat relates the detected differential pressure to the flow rate in step307. After determining the flow rate based on the differential pressuresignal at 307, the measurement processor 142 outputs a differentialpressure signal-based flow rate signal at 309.

Although the illustrated embodiment assesses the vortex signal frequencyat 305 to determine when to use the differential pressure signal togenerate the flow rate output of the flowmeter 101, other embodimentscan use other characteristics of the vortex signal or differentialpressure signal to make the same determination. For example, in oneembodiment (not shown), the measurement processor determines to use thedifferential pressure signal to generate the flow rate output when thedifferential pressure signal has a value that is less than a thresholdvalue that corresponds to a flow rate at which the process fluid islaminar or nearly laminar.

Referring still to FIG. 3 , when the vortex signal frequency isdetermined to be greater than the low flow cutoff frequency at 305, themeasurement processor 142 determines the flow rate based on the vortexsignal at step 311. The principles of calculating a flow rate (e.g.,flow velocity, volumetric flow rate, or mass flow rate) using thefrequency of a vortex signal are well-known to those skilled in the art.

In the illustrated embodiment, before outputting the vortex signal-basedflow rate measurement at step 313, the measurement processor 142 isconfigured to execute a verification subroutine 321. Initially, at 323the measurement processor 142 determines whether the differentialpressure detected by the sensor 203 is greater than the maximum pressurethreshold of the sensor. If the detected pressure is less than thesensor's maximum pressure threshold, the measurement processor 142determines the flow rate of the fluid based on the differential pressuresignal at 325. After determining the flow rate using both the vortexsignal (at 311) and the differential pressure signal (at 325), themeasurement processor 142 compares the two flow rate measurements at327. If at 328 the two flow rate measurements differ by less than athreshold amount, the processor 142 proceeds to output the vortexsignal-based flow rate measurement at step 313. However, if the two flowrate measurements differ by greater than the threshold amount, theflowmeter determines that there is an error condition and outputs analarm at 329. It will be appreciated that the measurement processor 142can be configured to execute the verification subroutine 321periodically (e.g., every n-times a vortex signal-based flow ratemeasurement is determined at 311; after the passage of a predeterminedinterval of time) or each time a vortex signal-based flow ratemeasurement is determined.

As can be seen, the illustrated flowmeter 101 extends the measurementrange of a conventional vortex flowmeter by providing an integrateddifferential pressure sensing arrangement 201 for sensing a differentialpressure that can be used to determine a flow rate of the process fluidwhen the shedding frequency is less than the low flow cutoff frequency.Thus, broadly speaking, the vortex flowmeter 101 includes one or moresensors 131, 203 that are each configured to generate a signalrepresenting the characteristics of the fluid as it flows through theflowtube 103 past the bluff body 121 and a measurement processor 142that is configured to use the signals to provide accurate flow ratemeasurement outputs across a wide range of flow conditions. For example,in one or more embodiments, the vortex flowmeter is configured togenerate a flow rate output representing the flow rate of the fluidbased exclusively on the signals from the one or more sensors 131, 203,wherein the flow rate output is produced and is reasonably accurate(e.g., has an error percentage of less than 10%, or less than 5%, orless than 3%, or less than 2%) when the fluid has a Reynolds number ofless than or equal to about 2,000, e.g., a Reynolds number of about1,000, a Reynolds number of about 500, and/or a Reynolds number of about250.

In one exemplary implementation, the vortex flowmeter 101 is used in afluid batch process. Fluid batch processes involve discrete batches offluid that flow from a source to a destination in succession. In anexemplary batch process, the flowmeter 101 is used to determine thetotal amount of fluid that flows in each batch. Throughout the fluidbatch process, the vortex sensor 131 detects the vortices that are shedas process fluid flows across a bluff body 121 and the pressure sensorarrangement 201 detects the differential pressure between the upstreamand downstream pressure tap locations L1, L2.

When each batch begins, the flowmeter 101 uses the differential pressuresignal from the pressure sensor arrangement 201 to determine the flowrate of the process fluid during an initial ramp-up portion of thebatch. The total amount of process fluid flow during the initial ramp-upportion of the process is calculated using the differential pressuresignal-based flow rate. The initial ramp-up portion of the batch endswhen the frequency of the vortex signal exceeds the low flow cutofffrequency. Following the initial ramp-up portion, during a middleportion of the batch, the flowmeter 101 uses the vortex signal from thevortex sensor 131 to determine the flow rate of the process fluid. Thetotal amount of process fluid flow during the middle portion of thebatch is calculated using the vortex signal-based flow rate. In anembodiment, the middle portion of the batch ends when the frequency ofthe vortex signal falls to less than the low flow cutoff frequency.After the middle portion is complete, during a final ramp-down portionof the batch, the flowmeter 101 uses the differential pressure signalfrom the pressure sensor arrangement 201 to determine the flow rate ofthe process fluid. The total amount of process fluid flow during thefinal ramp-down portion of the process is calculated using thedifferential pressure signal-based flow rate. Although only three phasesof flow rate measurement are mentioned above, it is understood that, incertain embodiments, the middle portion of a batch can be broken up byone or more additional phases of low process fluid flow during which theamount of process fluid flow is determined using the differentialpressure signal-based flow rate.

In one embodiment of the batch process described above, the measurementprocessor 142 locally determines the amount fluid flow during each ofthe initial ramp-up portion, the middle portion, and the final ramp-downportion based on the determined differential pressure signal-based flowrate and vortex signal-based flow rate, respectively. In anotherembodiment, the local measurement processor 142 outputs a differentialpressure signal-based flow rate and a vortex signal-based flow rate to aremote processor during the respective portions of the batch and theremote processor determines the amount of fluid flow during each portionof the batch. In either case, the total amount of process fluid flowduring the batch can be determined using the amounts of fluid flowdetermined for each of the initial ramp-up portion, the middle portion,and the final ramp-down portion based on the differential pressuresignal-based flow rate and the vortex signal-based flow rate,respectively.

EXAMPLE 1

To test the concept of using the differential pressure across a bluffbody to provide flow rate measurements, pressure taps were formed intwo-inch and four-inch diameter flowtubes 103 at two upstream locationsL1, L1′ and several downstream locations L2, respectively. During oneset of tests, the results of which are described in Table 1, below, adifferential pressure sensor was operatively connected to the two-inchdiameter flowtube 103 at an upstream pressure tap location L1′ spacedapart from the upstream end face 121A of the bluff body 121 by adistance UD of about 0.59 inches and a downstream pressure tap locationL2 spaced apart from the upstream end face 121A of the bluff body 121 bya distance DD of about 1.24 inches. The upstream tap location L1′ andthe downstream tap location L2 in the tests described in Table 1 werelocated at a circumferential region of the flowtube wall roughlyperpendicular to a radial axis of the bluff body.

During another set of tests, the results of which are described in Table2, below, a differential pressure sensor was operatively connected tothe two-inch diameter flowtube 103 at an upstream pressure tap locationL1 on the upstream end face 121A of the bluff body 121 and a downstreampressure tap location L2 spaced apart from the upstream end face 121A ofthe bluff body 121 by a distance DD of about 1.24 inches. The downstreamtap location L2 in the tests described in Table 2 was located at acircumferential region of the flowtube wall roughly perpendicular to aradial axis of the bluff body.

The results of another set of tests are described in Table 3, below, inwhich a differential pressure sensor was operatively connected to thefour-inch diameter flowtube 103 at an upstream pressure tap location L1′spaced apart from the upstream end face 121A of the bluff body 121 by adistance UD of about 0.60 inches and a downstream pressure tap locationL2 spaced apart from the upstream end face 121A of the bluff body 121 bya distance DD of about 1.88 inches. The upstream tap location L1′ andthe downstream tap location L2 in the tests described in Table 3 werelocated at a circumferential region of the flowtube wall roughlyperpendicular to a radial axis of the bluff body.

During another set of tests, the results of which are described in Table4, below, a differential pressure sensor was operatively connected tothe four-inch diameter flowtube 103 at an upstream pressure tap locationL1 on the upstream end face 121A of the bluff body 121 and a downstreampressure tap location L2 spaced apart from the upstream end face 121A ofthe bluff body 121 by a distance DD of about 1.88 inches. The downstreamtap location L2 in the tests described in Table 4 was located at acircumferential region of the flowtube wall in line with the bluff body.

Table 5, below, describes the results of another set of tests in which adifferential pressure sensor was operatively connected to the four-inchdiameter flowtube at an upstream pressure tap location L1′ spaced apartfrom the upstream end face 121A of the bluff body 121 by a distance UDof about 0.60 inches and a downstream pressure tap location L2 spacedapart from the upstream end face 121A of the bluff body 121 by adistance DD of about 1.88 inches. The upstream tap location L1′ and thedownstream tap location L2 in the tests described in Table 5 werelocated at a circumferential region of the flowtube wall in line withthe bluff body.

During each test, a quantity of water was directed through the flowmeter to a calibration tank. The rate at which the calibration take wasfilled was monitored to provide a precise control measurement of theflow rate. For each test, the tables below show the weight of water thatwas imparted through the flowmeter, the duration of time during whichthe water was delivered through the flowmeter, the median frequency ofthe vortex signal generated by the vortex sensor, a detected linepressure at the upstream pressure tap location, a measured linetemperature, control flow rate measurements (volumetric flow rate andflow velocity) determined using the control tank, a detecteddifferential pressure between the two pressure tap locations, andcalculated values for K and coefficient of discharge based on Equations1 and 2, below.

TABLE 1 2-Inch Flowtube; Perpendicular Pressure Taps at L1′, L2 Test 1 23 4 5 6 7 8 Total flow 2517 3509.7 2615.6 2586 3189 203.834 188.984149.172 weight (lb) Total flow 115.261 227.304 241.264 328.317 563.855135.656 192.385 345.704 time (sec) Vortex freq (Hz) 91.6 64.9 45.7 33.223.9 13.9 9.1 4.1 Up-stream line 12.759 19.169 22.407 23.914 24.75125.355 25.548 25.674 press. (psig) Line temp. (F.) 74.1 74.2 74.4 74.875.2 75.4 75.6 75.7 Contr. vol. 157.7 111.5 78.3 56.9 40.8 23.9 15.7 6.9flow rate (GPM) Contr. flow 17.2 12.1 8.5 6.2 4.4 2.6 1.7 0.75 vel.(ft/sec) DP (psi) 4.0 2.0 1.0 0.52 0.27 0.093 0.040 0.008 K 8.61 8.618.61 8.59 8.60 8.57 8.50 8.36 CoD 0.868 0.867 0.867 0.866 0.866 0.8630.856 0.842

TABLE 2 2-Inch Flowtube; Pressure Taps at L1, Perpendicular L2 Test 1 23 4 5 6 7 8 Total flow 2523.6 2660 2735.8 2558 1612.7 1568.9 152.414152.063 weight (lb) Total flow 116.351 128.524 166.392 213.936 200.403270.599 80.821 89.691 time (sec) Vortex freq (Hz) 91.1 86.9 69.2 50.433.9 24.5 17.5 15.7 Up-stream line 15.822 16.664 19.994 22.599 24.24524.917 25.309 25.386 press. (psig) Line temp. (F.) 68.8 69.2 69.5 69.870.2 70.4 68.5 68.8 Contr. vol. 156.5 149.3 118.7 86.3 58.1 41.8 30.027.0 flow rate (GPM) Contr. flow 17.0 16.3 12.9 9.4 6.3 4.6 3.3 2.9 vel.(ft/sec) DP (psi) 6.8 6.2 3.9 2.1 0.95 0.49 0.26 0.20 K 6.52 6.54 6.536.52 6.50 6.51 6.45 6.49 CoD 0.657 0.659 0.658 0.658 0.655 0.656 0.6500.654 Test 9 10 11 12 13 Total flow 201.306 155.31 151.178 151.102132.864 weight (lb) Total flow 139.78 132.236 180.331 318.36 517.667time (sec) Vortex freq (Hz) 13.3 10.9 7.8 4.5 2.5 Up-stream line 25.47725.56 25.65 25.707 25.723 press. (psig) Line temp. (F.) 69.1 69.4 69.669.9 70 Contr. vol. 22.9 18.7 13.3 7.6 4.1 flow rate (GPM) Contr. flow2.5 2.0 1.5 0.82 0.44 vel. (ft/sec) DP (psi) 0.15 0.10 0.052 0.017 0.005K 6.45 6.43 6.36 6.34 6.25 C_(d) 0.650 0.648 0.641 0.639 0.630

TABLE 3 4-Inch Flowtube; Perpendicular Pressure Taps at L1′, L2 Test 1 23 4 5 6 7 8 9 Total 4532.7 4545.4 4514.9 4575.5 3581.7 2570.6 2609.02588.4 2818.0 flow weight (lb) Total 57.6 75.3 104.5 148.6 187.3 205.4278.2 437.1 680.0 flow time (sec) Vortex 43.19 33.17 23.75 16.95 10.546.90 5.16 3.25 2.27 freq (Hz) Up- 14.3 18.9 22.2 23.9 25.0 25.4 25.525.6 25.7 stream line press. (psig) Line 76.8 74.5 74.6 74.7 76.3 76.276.4 76.6 76.8 temp. (F.) Contr. 568.0 435.6 312.0 222.3 138.1 90.4 67.742.8 29.9 vol. flow rate (GPM) Contr. 15.85 12.16 8.71 6.20 3.85 2.521.89 1.19 0.84 flow vel. (ft/sec) DP (psi) 3.44 2.02 1.03 0.53 0.200.0870 0.0493 0.0190 0.0050 K 8.541 8.561 8.566 8.556 8.573 8.551 8.5158.669 11.836 CoD 0.860 0.862 0.863 0.862 0.864 0.861 0.858 0.873 1.192Test 10 11 12 13 14 15 16 17 18 Total 2669.0 3650.7 2516.2 3122.0 2605.22631.4 2600.0 2668.8 2608.0 flow weight (lb) Total 673.6 560.3 644.3822.0 686.3 648.8 688.1 703.0 686.9 flow time (sec) Vortex 2.17 3.572.22 2.07 2.07 2.22 0.34 2.07 2.07 freq (Hz) Up- 25.6 25.6 25.7 25.725.7 25.7 25.7 25.7 25.7 stream line press. (psig) Line 77.3 78.3 79.078.0 78.0 79.0 75.0 78.3 78.4 temp. (F.) Contr. 28.6 47.1 28.2 27.4 27.429.3 27.3 27.4 27.4 vol. flow rate (GPM) Contr. 0.80 1.31 0.79 0.77 0.770.82 0.76 0.77 0.77 flow vel. (ft/sec) DP (psi) 0.0089 0.0240 0.00830.0080 0.0082 0.0090 0.0076 0.0079 0.0078 K 8.467 8.481 8.654 8.5608.431 8.645 8.763 8.623 8.646 CoD 0.853 0.854 0.872 0.862 0.849 0.8710.883 0.868 0.871

TABLE 4 4-Inch Flowtube; Pressure Taps at L1, Inline L2 Test 1 2 3 4 5 67 8 9 Total 5527.0 5520.6 4515.7 3509.8 3516.8 3550.8 2516.8 3520.82501.6 flow weight (lb) Total 80.4 98.8 118.2 129.3 187.8 298.8 319.0646.4 718.4 flow time (sec) Vortex 37.82 30.76 21.02 14.95 10.32 6.554.35 2.98 1.90 freq (Hz) Up- 19.42 21.51 23.69 24.66 25.19 25.50 25.6125.67 25.69 stream line press. (psig) Line 76.9 76.0 77.0 75.6 75.6 75.776.0 76.2 76.4 temp. (F.) Contr. 496.80 403.66 276.06 196.09 135.2385.83 56.99 39.34 25.15 vol. flow rate (GPM) Contr. 1.107 0.899 0.6150.437 0.301 0.191 0.127 0.088 0.056 flow vel. (ft/sec) DP (psi) 7.0824.724 2.208 1.123 0.534 0.217 0.0978 0.0455 0.0170 K 5.21 5.18 5.18 5.165.16 5.14 5.09 5.15 5.39 CoD 0.525 0.522 0.522 0.520 0.520 0.518 0.5120.519 0.543

TABLE 5 4-Inch Flowtube; Inline Pressure Taps at L1′, L2 Test 1 2 3 4 56 7 8 9 10 11 Total flow 5520.8 5536 4563.5 3529.2 3523.6 3512 3507.82512.6 3762 2582.8 2568.6 weight (lb) Total flow 74.2 88.2 102.3 115.3163.9 225.5 350.3 307.1 631.8 593.5 970.0 time (sec) Vortex freq (Hz)40.88 34.50 24.55 16.83 11.84 8.59 5.52 4.50 3.27 2.38 1.45 Up-streamline 17.08 19.50 22.50 24.16 24.91 25.29 25.52 25.57 25.63 25.66 25.69press. (psig) Line temp. (F.) 74.4 74.6 74.8 75.9 76.2 76.2 76.3 75.575.6 75.6 75.6 Contr. vol. 537.32 453.35 322.18 221.13 155.28 112.4772.33 59.09 43.01 31.43 19.12 flow rate (GPM) Contr. flow 14.99 12.658.99 6.17 4.33 3.14 2.02 1.65 1.20 0.88 0.53 vel. (ft/sec) DP (psi) 7.075.02 2.54 1.20 0.605 0.313 0.128 0.0868 0.0459 0.0228 0.0082 K 5.64 5.655.64 5.64 5.57 5.61 5.64 5.60 5.60 5.81 5.89 CoD 0.540 0.540 0.540 0.5400.533 0.536 0.539 0.536 0.536 0.556 0.564

$\begin{matrix}{K = \frac{V}{\sqrt{DP}}} & {{Equation}1}\end{matrix}$

Wherein:

-   -   V=flow velocity measured using control tank;    -   DP=measured differential pressure between pressure taps

$\begin{matrix}{C_{d} = {\frac{A1}{A2}*V*\frac{\sqrt{( {1 - \beta^{4}} )}}{\sqrt{2*{gc}*\rho}*{DP}}}} & {{Equation}2}\end{matrix}$

Wherein:

-   -   A1=cross sectional area of pipe;    -   A2=cross sectional area of throat;

${\beta = {{Beta}{Ratio}( \sqrt{\frac{A2}{A1}} )}};$

-   -   gc=gravitational constant;    -   p=density of fluid

When introducing elements of the present invention or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

In view of the above, it will be seen that the several objects of theinvention are achieved and other advantageous results attained.

As various changes could be made in the above products and methodswithout departing from the scope of the invention, it is intended thatall matter contained in the above description shall be interpreted asillustrative and not in a limiting sense.

What is claimed is:
 1. A vortex flowmeter for measuring a flow rate of afluid, the vortex flowmeter comprising: a flowtube; a bluff bodypositioned in the flowtube; one or more sensors, each sensor beingconfigured to generate a signal representing one or more characteristicsof the fluid as it flows through the flowtube past the bluff body; ameasurement processor configured to generate a flow rate outputrepresenting the flow rate of the fluid based on the signals from theone or more sensors when the fluid has a Reynolds number of less thanapproximately
 2300. 2. The vortex flowmeter of claim 1, wherein thebluff body positioned in the flowtube is configured for sheddingvortices in the fluid when the fluid flows through the flowtube, whereinthe one or more sensors comprises a vortex sensor configured to detectthe vortices and generate a vortex signal representing the detectedvortices, and wherein the measurement processor is configured togenerate the flow rate output using the vortex signal when the fluid hasa Reynolds number of greater than approximately
 2300. 3. The vortexflowmeter of claim 2, wherein the one or more sensors comprises apressure sensor arrangement configured to detect a differential pressurein the fluid between a first location upstream of at least a portion ofthe bluff body and a second location downstream of at least a portion ofthe bluff body and generate a differential pressure signal representingthe differential pressure, and wherein the measurement processor isconfigured to generate flow rate output using the differential pressuresignal when the fluid has a Reynolds number of less than approximately2300.
 4. The vortex flowmeter of claim 3, wherein measurement processoris connected to the vortex sensor and the pressure sensor arrangement toreceive the vortex signal and the differential pressure signal,respectively, wherein the measurement processor is further configured todetermine a vortex signal-based measurement of the flow rate using thevortex signal and to determine a pressure signal-based measurement ofthe flow rate using the differential pressure signal, and wherein themeasurement processor is further configured to compare the vortexsignal-based measurement and the pressure signal-based measurement. 5.The vortex flowmeter as set forth in claim 4, wherein the measurementprocessor is further configured to compare a characteristic of at leastone of the vortex signal and the differential pressure signal to athreshold and selectively use the vortex signal to generate the flowrate signal when the determined characteristic is greater than thethreshold and use the differential pressure signal to generate the flowrate signal when the determined characteristic is less than thethreshold.
 6. The vortex flowmeter as set forth in claim 5, wherein thedetermined characteristic is a frequency of the vortex signal and thethreshold is a cutoff frequency of the vortex flowmeter representing alower bound at which the measurement processor generates the flow rateoutput using the vortex signal.
 7. The vortex flowmeter as set forth inclaim 4, wherein the measurement processor is further configured toprovide an alarm when the vortex signal-based measurement deviates fromthe pressure signal-based measurement by more than a predeterminedamount.
 8. The vortex flowmeter as set forth in claim 3, wherein thebluff body has an upstream end face and the flowtube has a longitudinalaxis and an inner diameter.
 9. The vortex flowmeter as set forth inclaim 8, wherein the first location is on the upstream end face.
 10. Thevortex flowmeter as set forth in claim 8, wherein the first location isspaced apart upstream of the upstream end face along the longitudinalaxis by a distance in an inclusive range of from about 0.0-times theinner diameter to about 4.75-times the inner diameter.
 11. The vortexflowmeter as set forth in claim 8, wherein the second location is spacedapart downstream of the upstream end face along the longitudinal axis bya distance in an inclusive range of from about 0.333-times the innerdiameter to about 5.0-times the inner diameter.
 12. The vortex flowmeteras set forth in claim 3, wherein the pressure sensor arrangementcomprises a differential pressure sensor unit including a sensingdiaphragm having a first side and an opposite second side.
 13. Thevortex flowmeter as set forth in claim 12, further comprising firstpassaging configured to convey pressure from the first location to thefirst side of the sensing diaphragm and second passaging configured toconvey pressure from the second location to the second side of thesensing diaphragm.
 14. The vortex flowmeter as set forth in claim 13,wherein the first passaging comprises a hole formed in at least one ofthe flowtube and the bluff body and the second passaging comprises ahole formed in the flowtube.
 15. The vortex flowmeter as set forth inclaim 3, wherein the flowtube comprises a single piece of materialhaving a length, each of the first and second locations being locatedalong the length.
 16. A method of determining a total quantity of fluidin a batch process, the method comprising: detecting vortices shed by abluff body positioned in a flowtube of a vortex flowmeter as the fluidflows across the bluff body during the batch process; detecting adifferential pressure across the bluff body during the batch process;determining a first amount of fluid that flows past the bluff bodyduring an initial portion of the batch process based on the detecteddifferential pressure; determining a second amount of fluid that flowspast the bluff body during a middle portion of the batch process basedon the detected vortices; and determining a third amount of fluid thatflows past the bluff body during a final portion of the batch processbased on the detected differential pressure.
 17. The method as set forthin claim 16, wherein detecting the differential pressure comprisesdetecting the differential pressure in the fluid between a firstlocation upstream of at least a portion of the bluff body and a secondlocation downstream of at least a portion of the bluff body.
 18. Themethod as set forth in claim 16, further comprising defining the middleportion of the batch process as occurring when the fluid has a Reynoldsnumber less than approximately
 2000. 19. The method as set forth inclaim 16, further comprising defining the initial portion of the batchprocess as occurring when the fluid has a Reynolds number greater thanapproximately
 2300. 20. The method as set forth in claim 16, furthercomprising defining the final portion of the batch process as occurringwhen the fluid has a Reynolds number less than approximately 2000.